Integrated containment system

ABSTRACT

Embodiments of the invention generally provide a containment system having integrated bubble tight-dampers. In another embodiment, the containment system includes an integral auto-scan mechanism disposed in the housing of the containment system so that a filter element, disposed in the housing, may be leak tested without accessing the interior of the housing. In yet another embodiment, a method for testing a filter disposed in a containment system includes challenging an upstream side of a filter element disposed in a housing of the containment system with a test aerosol, and automatically moving a probe disposed within the housing to obtain samples for leak testing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/007,843 filed Jan. 17, 2011, which is a continuation of U.S. patentapplication Ser. No. 12/819,732 filed Jun. 21, 2010, now U.S. Pat. No.7,896,938 B2, which is a continuation of U.S. patent application Ser.No. 11/380,737 filed Apr. 28, 2006, now U.S. Pat. No. 7,758,664 B2,which claims benefit from U.S. Provisional Patent Application No.60/706,516, filed Aug. 9, 2005, all of which are incorporated byreference in their entireties. This application is related to U.S. Pat.No. 7,658,787 B2 issued to Thomas C. Morse entitled “EXHAUST FILTERMODULE WITH MECHANICALLY POSITIONABLE SCAN PROBE”, which is alsoincorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention generally relates to a containment housing havingintegrated dampers. The invention also relates to a containment housinghaving an integrated filter leak scanning mechanism.

2. Description of the Related Art

FIG. 1 depicts a conventional containment system. A conventionalcontainment system typically consists of multiple components arranged inseries. The components generally include one or more filter housingsections, an upstream test section, a downstream test section androtating vane-type bubble-tight dampers for isolating the system fromthe upstream and downstream ductwork to which the system is coupled.

The bubble-tight dampers are located upstream and downstream of thefilter housing and test sections, which allow the containment system tobe sealed air-tight during system decontamination and/or filterservicing. Transitions are disposed between the bubble-tight dampers andthe testing and other components of the containment system. The dampersmay be bolted or welded to the transitions.

The upstream test section is for the introduction of a challenge aerosolupstream of the filter components and for the measurement of upstreamchallenge concentration. Conventional upstream test sections typicallyinclude baffles to achieve adequate aerosol mixing such that testing maybe performed to ANSI, IEST or other standard. The filter housingsections may hold one or more prefilters, intermediate filters, HEPAfilters, HEGA filters and/or other filtration components required forthe specific application. It is contemplated that the filter 104 may bea panel filter, v-bank filter or other type of filter configuration.

The scan test section is used to conduct manual in-place scan testingand validation of the HEPA filter(s) to determine the location and sizeof any leaks in the filter(s). A bag with gloves (not shown) isgenerally coupled to a door flange of the scan test section and utilizedto position a probe during testing of a filter disposed in the filterhousing section.

This configuration for a conventional containment system is very large,typically in the range of about 130 inches in length, and requiressignificant space and cost for installation. Moreover, the large size ofthe components, typically fabricated from stainless steel, results inhigh material costs. Furthermore, each access door, bag ring, and jointbetween the multiple sections is a potential leak point. As containmentsystems are relied upon in labs testing the most toxic and virulentchemicals, agents, viruses and organisms, each potential leak pointrepresents a source for a potential catastrophic biohazard release thatcould expose technicians and/or the surrounding environment.

Thus, there is a need for an improved containment system having smallerfoot print and lower fabrication costs, which also improves the system'sinherent safeguards against potential leaks.

SUMMARY OF THE INVENTION

Embodiments of the invention generally provide a containment systemhaving integrated bubble tight-dampers. In another embodiment, thecontainment system includes an integral auto-scan mechanism disposed inthe housing of the containment system so that a filter element, disposedin the housing, may be leak tested without accessing the interior of thehousing.

In yet another embodiment, a method for testing a filter disposed in acontainment system includes challenging an upstream side of a filterelement disposed in a housing of the containment system with a testaerosol, and automatically moving a probe disposed within the housing toobtain samples for leak testing.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of the specification, schematically illustrate the presentinvention, and together with the general description given above and thedetailed description given below, serve to explain the principles of theinvention.

FIG. 1 is a side view of a conventional containment system;

FIG. 2 depicts one embodiment of a containment system having integratedbubble-tight dampers;

FIG. 3A is a partial sectional view of the containment system of FIG. 2illustrating one embodiment of a bubble-tight damper;

FIG. 3B is a partial sectional view of the containment system of FIG. 2illustrating an alternative location for an aerosol injection ring;

FIG. 4 is a partial top view of the containment system of FIG. 2illustrating one embodiment of an aerosol injection ring;

FIG. 5 depicts a section view of the containment system of FIG. 2;

FIG. 6 depicts a partial section view of a bag ring coupled to thehousing of the containment system of FIG. 2;

FIG. 7 depicts another embodiment of a containment system; and

FIG. 8 depicts one embodiment of an autoscan mechanism that may beutilized in a containment system.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures. It is contemplated that elements of one embodiment may bebeneficially incorporated in other embodiments.

DETAILED DESCRIPTION

The present invention includes one or more of the following features:

-   -   Filter housing(s) and test sections incorporated into a single        housing, thereby eliminating potential leak points such as        multiple bolted or welded connections of individual sections.    -   Damper blade and sealing surface are integrated into a        containment housing as opposed to being a separate damper.    -   Damper utilizes the body of the containment housing as the        external pressure boundary, as opposed to a separate housing        such as the barrel of a damper (such as shown in the        conventional system depicted in FIG. 1).    -   The damper “seal plate” or sealing surface and inlet flange are        attached directly to the end of the containment housing. They        are an integral part of the containment housing.    -   Beneficially, the integrated damper eliminates potential leak        points such as multiple bolted or welded connections (e.g., such        as the damper and transition shown in the conventional system        depicted in FIG. 1).    -   The damper blade remains facing in the inlet air stream during        operation. Thus, the damper blade also functions as distribution        plate to ensure compliance with: IEST-RP-CC034.1 for aerosol        uniformity and/or IEST-RP-CC002.2 for airflow uniformity and/or        airflow distribution per ASME N510, Section 8, 1995 Reaffirmed        and/or air-aerosol mixing uniformity per ASME N510, Section 9,        1995 Reaffirmed. This eliminates the need for internal baffles        and space for mixing, thereby allowing the housing to be        shortened.    -   The design and location of the aerosol injection ring is such        that aerosol is injected into the high-velocity air coming        through the inlet collar of the upstream damper. The location of        the aerosol injection ring relative to the damper eliminates the        need for distribution plates further downstream of the damper.        Whereas, conventional systems utilize separate dampers and        aerosol injection housings.    -   The combination of the aerosol injection ring design and        position relative to the damper, the design of the damper, and        the location of the damper and aerosol injection ring relative        to the inlet of the containment housing comprise an “integrated        system” that typically consists of several individual components        welded together in series (e.g., a damper, and test section).        This integrated system reduces the overall length, installation        costs, manufacturing costs, and the installation space        requirements as compared to conventional containment systems.    -   An integrated autoscan mechanism is provided in the housing of        the containment system. This allows filters, disposed in the        containment system, to be tested without opening and exposing        technicians to the downstream interior side of the filter        housing.

FIG. 2 shows a containment system 100 having integrated dampers 118. Thecontainment system 100 generally includes a housing 102 which sealinglyholds a filter element or filter 104 therein. In one embodiment, thehousing 102 includes a bottom 108, sidewalls 106 (of which the front,left end, and right end sidewalls are shown) and a top 110. The housing102 may be fabricated from any suitable material such as plastic,fiberglass, stainless steel and aluminum, among other suitablematerials. In the embodiment depicted in FIG. 1, the bottom 108,sidewalls 106 and top 110 are continuously welded into a single housing102 having a substantially rectangular shape.

Referring additionally to the sectional view of FIG. 3A, the housing 102includes collars 116 disposed around inlet and outlet apertures 186, 188formed in opposing parallel sidewalls 106. The collars 116 are sealinglycoupled to or formed in the sidewalls 106 to facilitate the flow of air(or other fluid) though the filter 104 disposed in the containmentsystem 100. The collars 116 may be sealed to the housing 102 by acontinuous weld, caulk, gasket or other suitable seal. The collars 116include a sealing lip 112 that extends into the interior volume of thehousing 102.

A bubble-tight damper 118 is provided in each collar 116. The damper 118may be moved to between a first position that sealingly engages the lip112, thereby preventing leakage through the collar 116, and a secondposition spaced-apart from the lip 112. The distance between the damper118 and lip 112 may be set to control the rate of flow through thecollar 116. In one embodiment, the damper 118 has a generally conicalshape that remains in a fixed orientation relative to the damper's openand closing motion, which is axially along the centerline of the collar116. Thus, as the damper 118 remains facing the flow (e.g., the face ofthe damper is maintained at a right angle to the flow) through thecollar 116, a uniform air gap is maintained between the damper and lip112 of the collar 116 resulting in uniform air flow distribution throughthe damper's full range of motion. One damper that may be adapted tobenefit from the invention is described in U.S. patent application Ser.No. 10/863,629 filed Jun. 8, 2004, by Morse et al., which is herebyincorporated by reference in its entirety.

In the embodiment depicted in FIG. 3A, the damper 118 includes agel-filled track 132 formed at the perimeter of a conical body thatselectively provides a bubble-tight seal when engaged with the lip 112extending from the housing 102 and/or collar 116. The phrase “conicalbody” is intended to include conical, ellipsoidal, hemispherical andround in forms, along with variations thereof. The gel may be a silicongel, polyurethane gel, or other material suitable for selectivelysealing the damper 118 to the containment system 100. Alternatively, abubble-tight seal may be formed by a gasket or other suitable material.The bubble-tight seal allows an interior volume of the containmentsystem 100 to be isolated from the ducts (not shown) coupled to thecollar 116. In this manner, the interior volume of the housing 102 maybe decontaminated and/or the filter 104 be replaced. As the damper 118is integrated directly into the housing 102 without transitions and/or aseparate damper module (as shown in the conventional system depicted inFIG. 1), multiple potential leak points are eliminated, increasing theinherent safety factor of the containment system 102 to inadvertentleakage and possible release of contaminants.

Referring additionally to the partial top view of the containment system100 depicted in FIG. 4, an aerosol injection ring 302 is disposed in thecollar 116 upstream of the damper 118. The aerosol injection ring 302 iscoupled by a tube 304, sealingly passing through the lip 112, to anaerosol injection port 180 formed through the housing 102. The aerosolinjection ring 302 is positioned in the high velocity flow of areadefined by the collar 116. Aerosol, provided to the air stream throughholes positioned on the radially inward side (or other portion) of theaerosol injection ring 302, impinges on the face of the damper 118 asthe air stream enters the housing 102, thereby proving the turbulencenecessary to ensure good mixing and uniform distribution of aerosol forfilter testing.

FIG. 3B is a partial sectional view of the containment system of FIG. 2illustrating an alternative location for an aerosol injection ring 330.The injection ring 330 is positioned inside the housing 102 and outwardfrom the lip 112. The injection ring 330 is disposed between thesidewall 106 and damper 106. Holes 402 formed in the injection ring 330have an orientation (shown by dashed line 332) which directs the sprayof aerosol into the housing 102 at an inward angle (e.g., toward thecenterline of the collar 116) such that the spray is directed into thehigh velocity air flow zone defined between the lip 112 and damper 118.The orientation 332 may also be away from the sidewall 106 so that thespray exiting the holes 402 clears the lip 112.

These configurations of the aerosol injection ring 330 as shown in FIGS.3A-B have demonstrated compliance with, IEST-RP-CC034.1 for aerosoluniformity, and/or IEST-RP-CC002.2, for airflow uniformity and/orairflow distribution per ASME N510, Section 8, 1995 Reaffirmed, and/orair-aerosol mixing uniformity per ASME N510, Section 9, 1995 Reaffirmed.Thus, the need for internal baffles and space for mixing required inconventional contamination systems is eliminated, thereby allowing thehousing to be shortened, as compared to conventional containmentsystems.

FIGS. 5-6 are sectional and partial sectional views of the contaminationsystem of FIG. 2. Referring primarily to FIG. 5, an autoscan mechanism130 may be disposed in the housing 102 to facilitate scanning of thefilter 104 without opening the housing 102. Since this area of thehousing 102 no long requires door to facilitate testing (such as theconventional system of FIG. 1), the length of the housing 102 may befurther reduced. Moreover, as no door is required, another potentialleak point present in conventional systems is eliminated, furtherincreasing the safety factor of the present invention. In oneembodiment, the total length of the housing 102 configured forautoscanning is less than about 55 inches. It is contemplated that airfrom a containment system configured for efficiency testing may besampled downstream of the housing 102, thus, allowing the distancebetween the downstream damper 118 and filter 104 to be furthershortened. One autoscan mechanism that may be adapted to benefit fromthe invention is described in U.S. Pat. No. 7,658,787 issued on Feb. 9,2010 to Morse et al., which is hereby incorporated by reference in itsentirety.

The autoscan mechanism 130 includes at least one probe 142 and motionmechanism, such as an actuator 144. The probe 142 may have any number ofdesigns suitable for particulate scan testing. In one embodiment, theprobe 142 conforms to IEST-RP-CC034.1 Recommended Practices. The probe142 is generally coupled by a tube 516 coupled to a downstream sampleport 508 defined through the housing 102. A tester 510, such as aphotometer or particle counter, is coupled to the port 508. The tester510 may also be coupled to the upstream sample port 540. The probe 142is generally configured to produce isokinetic sampling at a predefinedfilter test velocity. It is contemplated that multiple probes, or aprobe having multiple sampling ports (and hence, multiple sampling tubes516 coupled to multiple sampling ports 508) may be utilized.

The actuator 144 may be one or more linear actuators, x/y actuators orother mechanisms suitable for positioning the probe 142 relative to thefilter element 104 thereby facilitating leak testing. Controls and/orutilities for the actuator 144 may be routed through ports 502 definedthrough the housing 102 to a controller 506. The ports 502 areconfigured to prevent leakage from the housing 102, and may be fittedwith a quick-disconnect or other suitable fitting. Such ports arecurrently available on containment systems available from Camfil Farr,Inc.

FIG. 8 depicts one embodiment of an autoscan mechanism 800 that may beused in the housing 102 described herein to leak test a filter installedin the system 100 without opening the housing 102. The autoscanmechanism 800 includes a motion mechanism 844 utilized to position theprobe 142 within the housing such that the entire face of the filter maybe scanned for leaks. The probe 142 may be positionable to leak test thefilter-to-sealing face seal for leaks as well. The motion mechanism 844may be one or more of any suitable actuator, robot, x-y actuator, alinear actuator, a stepper or servo motor, a fluid power cylinder, arod-less cylinder, a chain or belt drive, a rack and pinion geararrangement, a ball, lead, acme or other power screw, or other suitablemotion control, motion generating and/or motion facilitating mechanismsuitable for moving the probe 142 within the interior volume of thehousing 102. In the embodiment depicted in FIG. 8, the motion mechanism844 is two rod-less cylinders 846, 848.

The first cylinder 846 is coupled to the housing 102 and has a firstcarriage 810 slideably coupled thereto. The second cylinder 848 iscoupled to and moves with the first carriage 810. The second carriage812 rides along the second cylinder 848. The probe 142 is coupled to thesecond carriage 812. The position of the first carriage 810 iscontrolled by selectively applying air or other fluid to at least oneside of the first cylinder 846. Likewise, the position of the secondcarriage 812 is controlled by selectively applying air or other fluid toat least one side of the second cylinder 848. Thus, by controlling themotion of the carriages 810, 812, the probe 142 may be selectivelypositioned to scan the face of the filter. In the embodiment shown,fluid control lines 822, 824 are provided between the cylinders 846, 848and ports 502 to control the lateral position of the probe 142 in thescan direction from outside of the system 100.

Sensors disposed in the system 100 may be utilized to provide to thefeedback controller for determining the position of the probe 142. Thisinformation may be utilized to confirm leaks, or to test filter leakrepairs, among other uses. In the embodiment depicted in FIG. 8, twosensors 852, 854, are wired to a controller 506 through the ports 502 toprovide information that may be utilized to determine when the probe 142is in a predefined position. The wiring between the sensors 852, 854 andthe controller 506 has been omitted for the sake of clarity. The sensors852, 854 may be utilized in calibration routines, or to calculate theprobe position utilizing a known or calculated rate of probe travel. Theprobe travel rate may be determined empirically, calculated based onknown or estimated rates associated with control fluid parameters (i.e.,pressure, volume and/or rate of fluid passing through control lines 848,850) and/or by direct measurement.

In another embodiment, the sensors 852, 854 are disposed in the housing102 to obtain a metric indicative of probe position. The sensors 852,854 may be an optical device, a proximity sensor, a rotary encoder, alinear variable differential transformer (LVDT) transducer or otherdevice suitable for determining the position of the probe 142. In theembodiment depicted in FIG. 8, the sensor 852, 854 are LVDT transducerswired to the controller 506 through the ports 502.

Returning to FIGS. 2 and 5, the housing 102 generally includes a door520 that may be utilized to sealingly close a filter access port 522.The door 520 generally includes a gasket 524 that may be compressedagainst the housing 102 to seal the port 522. In one embodiment, thegasket 524 is compressed by a locking mechanism 526, such as a knobdisposed on a threaded member. As the housing 102 only requires a singledoor or access port for accessing the interior of the housing 102 (e.g.,solely the filter access port 522), the number of potential leak pointsare minimized to solely the single door, the housing edge welds, and thepenetrations, thus providing a more robust and reliable containmentsystem as compared to conventional systems. As the critical nature ofthe hazard level associated with the use of containment systemscontinues to increase, containment systems, such as the inventiondescribed herein having minimized leak potential, will become anecessity for protecting technicians and the areas surrounding the labsutilizing these systems.

Continuing to refer to FIGS. 2 and 5, a bag ring 530 circumscribes thefilter access port 522. The ring 530 provides a mounting flange for abag (optionally with gloves) 532 may be utilized to remove and/or accessthe interior of the housing 102 as know in the art. This method foraccessing the interior of the housing is generally known as “bag-in,bag-out”, and is described in further detail in U.S. Pat. No. 4,450,964,which is incorporated by reference in its entirety.

The filter 104 is generally sealed against a sealing face 550 disposedin the housing 102. The sealing face 550 is coupled to the housing 102in a manner that forces air, flowing through the housing, to passthrough the filter 104. In one embodiment, the sealing face 550 is aknife edge for engaging a fluid seal formed in a frame of the filter104. It is contemplated that the sealing face 550 may be a flange forseating a gasket, among other configurations suitable for sealing thefilter 104 to the housing 102.

The housing 102 also includes a biasing mechanism 552. The biasingmechanism 552 generally urges the filter 104 against the sealing face550 to ensure no by-passage during operation. In one embodiment, thebiasing mechanism 552 is a linkage clamping mechanism which may be movedbetween a position that releases the filter 104, and a position thatbiases the filter against the sealing face 550. It is contemplated thatother configurations of a biasing mechanism 552 may be utilized that aresuitable for holding the filter 104 against the sealing face 550. Onecontamination housing that may be adapted to benefit from the inventionhaving both a biasing mechanism, bag ring and filter access port is a FBHOUSING™, available from Camfil Farr, Inc., located in Washington, N.C.

FIG. 7 depicts another embodiment of a containment system 700 havingintegrated dampers 118. The containment system 700 is generally similarto the system of FIGS. 2-6, except wherein the system 700 includes asecond access port 702 with bag ring 704 to accommodate manual testingof the filter 104 utilizing conventional scanning practices using a bagwith gloves, such as the bag 532 shown in FIG. 5.

Thus, a containment system having at least one integrated damper isprovided that has a substantial reduction in overall size and costcompared to conventional containment systems. Moreover, embodimentshaving an autoscan mechanism that enable testing of a filter in itsinstalled location (e.g., operational location at the final users site,not bench testing) without opening the housing and exposing the areadownstream of the filter to the risk of contamination.

1. A containment system comprising: a housing having an airflow inletaperture and an airflow outlet aperture; a first collar extending fromthe housing and circumscribing the inlet aperture; a first damperoperable to regulate flow through the inlet aperture circumscribed bythe first collar; and an aerosol injection ring disposed in the housingadjacent the first damper.
 2. The containment system of claim 1, whereinthe containment system further comprises: a filter sealing portiondisposed in the housing between the inlet and outlet apertures; a secondcollar extending from the housing and circumscribing the outletaperture; and a second damper operable to regulate flow through theoutlet aperture.
 3. The containment system of claim 1, furthercomprising: a single selectively sealable access aperture formed throughthe housing; and a bag-in/bag-out ring extending from the housing andcircumscribing the access aperture.
 4. The containment system of claim1, wherein the first damper moves axially relative to a center line ofthe first collar.
 5. The containment system of claim 4, wherein thefirst damper further comprises: a substantially conical body.
 6. Thecontainment system of claim 5, wherein the conical body is in conical,ellipsoidal, hemispherical or round in form.
 7. The containment systemof claim 1, further comprising: a scan probe disposed in the housing;and a motion mechanism disposed in the housing configured to displacethe scan probe.
 8. The containment system of claim 7, wherein the scanprobe further comprises: an elongated member; and a plurality of sampleports formed in the elongated member.
 9. The containment system of claim7, further comprising: a plurality of penetrations formed through thehousing, at least one of the penetrations being coupled to the scanprobe.
 10. The containment system of claim 1, wherein the aerosolinjection ring further comprises: a plurality of aerosol injection holeshaving a radially inward orientation.
 11. The containment system ofclaim 1, wherein the first damper further comprises: a sealing elementthat provides a bubble-tight seal when the first damper is in a closedposition.
 12. The containment system of claim 11, wherein the firstcollar further comprises a lip.
 13. The containment system of claim 12,wherein the sealing element of the first damper engages the lip when thefirst damper is in the closed position.
 14. The containment system ofclaim 1, wherein the first damper is disposed in the first collar.
 15. Acontainment system comprising: a housing having an airflow inletaperture and an airflow outlet aperture, the housing confining aninterior volume comprising a first region separated from a second regionby a sealing portion, the sealing portion configured to provide anair-tight interface with a filter element when disposed in the housing;a first collar extending from the housing and circumscribing the inletaperture; a first damper disposed adjacent the first collar and operableto regulate flow through the inlet aperture; a second collar extendingfrom the housing and circumscribing the outlet aperture; and a seconddamper disposed adjacent the second collar and operable to regulate flowthrough the outlet aperture; and an aerosol injection ring disposed inthe first region of the housing and having a plurality of radiallyinward oriented aerosol injection holes.
 16. The containment system ofclaim 15, wherein the aerosol injection ring is disposed outward of thefirst collar and between the first damper and a wall of the housinghaving the inlet aperture formed therein.
 17. The containment system ofclaim 15, further comprising: a selectively sealable access apertureformed through the housing; and a bag-in/bag-out ring extending from thehousing and circumscribing the access aperture.
 18. The containmentsystem of claim 15, further comprising: a motion mechanism disposed inand coupled to the housing; and a probe coupled to and selectivelydisplaced by the motion mechanism.
 19. The containment system of claim15, wherein the first damper further comprises: a sealing element thatprovides a bubble-tight seal when the first damper is in a closedposition.
 20. A method for replacing a filter disposed in a containmenthousing, comprising: moving a first damper disposed in a housing to aclosed position that provides an air-tight seal of an inlet of thehousing; moving a second damper disposed in the housing to a closedposition that provides an air-tight seal of an outlet of the housing;opening an access door having bagging ring coupled to the housing;performing an bag-in/bag-out filter exchange through the access door toinstall a replacement filter in the housing; testing the replacementfilter disposed in the housing with a scan probe disposed in the housingwithout opening the housing; and moving the first damper and the seconddamper to an open position that allows air flow through the containmenthousing.